Improvement of hydraulic control quality for deep drawing presses through retrofit Speaker: M. Helmke TRsystems GmbH 09.03.2016 10 th International Fluid Power Conference
Outline & Introduction Outline 1. Introduction 2. Tasks and Machines 3. Solution 4. Results 5. Conclusion Source: Drive Automotive Industries of America Inc. Introduction retrofit for presses every 10-15 years (electrical) some machines have hydraulic closed loop control system (die cushions (DC), ram cushions, hydraulic ram) most machine manufactures use of the rack control system special applications need special engineered solutions approach by TRsystems is a tailored control solution Slide 2
Tasks and Machines Arisa S-4-1600-470-230 LDE mechanical transfer press with Link-Drive engine 10 separate hydraulic die cushions 2 servo valves per cushion 3-chamber cylinder for every cushion Year of manufacture 2005 Ram (force, stroke) Stroke speed Cushion (force, stroke) 16.000 kn, 600 mm 8 30 1/min. 600 kn, 200 mm MW ZE2100.45.2.2 hydraulic tryout press with MultiCurve-technology 4 separate s accumulator drive for forming stroke 8 separate pressure cylinders for die cushion Year of manufacture 2006 Ram (force, stroke) Speed (pressing, rapid down) Cushion (force, stroke) 21.000 kn, 1500 mm 500 mm/s, 350 mm/s 6.000 kn, 350 mm Slide 3
Tasks and Machines pressure [bar] Task for the retrofit 400.0 360.0 320.0 280.0 240.0 200.0 160.0 120.0 80.0 40.0 0.0 electrical retrofit of all 10 cushions hydraulic remains untouched closed loop control for Before retrofit DC pressure and positioning function target pressure actual pressure 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 time [s] heavy pressure overshoots and permanent oscillations no consistent component quality Task for the retrofit electrical retrofit of whole machine new servo valves for all DC pressure cyl. closed loop control for Before retrofit DC pressure and positioning function ram pressure, velocity and parallelism function no constant DC forces, esp. for higher die speeds fluctuations within ram s velocity control Slide 4
Tasks and Machines Ram velocity control ram velocity [mm/s] down up trajectory should look like trajectory of a mechanical press rapid down die closed time [s] lifting velocity rapid up velocity ram position [mm] top stop down closing stroke forming return stroke up top stop brake distance die closed bottom stop acceleration distance lifting off lifting time [s] DC pressure control Slide 5
Solution Hardware Hardware existing control system replaced by Beckhoff IPC existing Beckhoff control system renewed communication between S7 (840D) and Beckhoff via Profibus DP/DP new servo valves for DC pressure function (from 40 Hz to 50 Hz frequency) 1 IPC controls all 10 die cushions EtherCAT I/O-modules EtherCAT I/O-modules with 16 bit resolution for analogue inputs and outputs new motion sensors for ram s parallelism and velocity control User level periphery level control level EtherCAT Profibus Siemens S7 Beckhoff -PC 6930 position sensor I/O-module pressure sensor valve 125 µs cycle time real-time capable Control level Periphery level Position sensor Box-PC C6150-0040 Switch I/O- Module Sensors Proportional technique Drives Safety I/O Safety Switch Safety Gateway PSS4000 CPU-Module Profinet SafetyNet p EtherCAT Profibus Slide 6
Solution Software real-time extension Beckhoff TwinCAT (PLC, visualization and closed loop control) control algorithms are written in C++ and executed in ring 0 (kernel mode) control algorithms include cam gear, trajectory generation, pressure-/position-/velocity-/parallelismcontrol DC pressure control PI-controller (10% of sum signal) and model based feed forward control (90% of sum signal) feed forward control is implemented as a 3-dimensionl valve characteristic pressure interpolation p set bar x ram mm / s e bar K i K p interpolating PI-controller value limitation controller limitation value limitation U V x actual system mm p actual bar integrator limitation Slide 7
Solution Ram velocity control trajectory generation (5th order, jolt-free) velocity control consists of PI-controller and model based feed forward control feed forward control was optimized via implementing valve s opening profile (servo cartridge Rexroth 2WRCE) Source: Bosch-Rexroth Ram parallelism control 4 position signal (every cylinder has its own sensor) position differences (tilting) are converted in tilting moments around x- and y-axis tilting moments are converted in resulting forces at cylinder center target value is 0.0 kn in order to eliminate tilting no interference between position-/velocity control and parallelism control Slide 8
Results DC pressure control before retrofit Ram velocity control before retrofit pressure [bar] 400.0 360.0 320.0 280.0 240.0 200.0 160.0 120.0 80.0 40.0 0.0 target pressure actual pressure 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 time [s] after retrofit after retrofit Slide 9
Results DC pressure control before retrofit after retrofit Slide 10
Results Ram parallelism control 3.800 mm rear-left -B front-left rear-right +B front-right y 1.700 mm rear-left +A front-left rear-right -A front-right y x x Slide 11
Conclusion Conclusion retrofit has led to enormous enhancement of closed loop control quality quality improvement achieved by changes in hardware new servo valves fast and real-time control systems model based control algorithms led to new level of stability consistent component quality ensured Outlook self-optimizing and self-adjusting control algorithms reducing commissioning time condition monitoring Research project adaptive control compensation of wear using of faster IPCs and servo valves Slide 12